Heat-resistant wall panel



Sept 22 1942@ y w. H. MARCHANT n 22969392 HEAT*RESISTANT WALL PANEL Filed Feb. 28, 1940 Patented Sept. 22, I19,42 l

UNITED STATES PATENT GFEICE.

2,296,392 HEAT-RESISTANT WALL PANEL William E. Merchant, South Pasadena, Calif Application February ze, 1940, serial N6. 321,280 4 claims. (cl. 'z2-iol) This invention relates to furnace construction and particularly pertains to a heat-resistant wall panel for furnaces and the like and method of making the same.

Inv the construction of furnaces it is common l practice to line the walls with some type of a large radiant section, the furnace lining covers an area of great expanse and is subjected to the expansive and contractional actionA due to temperature change within the furnace, with the result that after the furnace has been fired the entire refractory lining is filled with line cracks throughout and upon repeated heating and cooling of the wall parts of the lining defined by the cracks will eventually break out. Various types of refractory lining have been used ranging from fire-brick laid in courses to plastic material spread in a solid layer as a wall lining. It is desirable to provide furnace lining in units which may be placed in position easily and which are formed in part at least with heatresistant material designed and arranged so that it may expand and contract without checking and cracking. It is the principal object of the present invention, therefore, to provide a furnace Y panel having a rigid backing to which heat-resistant material is applied in a layer and bonded therewith, and which layer of heat-resistant material comprises a plurality of separate blocks or sections initially' delineated by combustible separating elements, which after burning out leave heat-resistant material is placed, said backing plate carrying means whereby the layer of heatresistant material may b e bonded thereto, the mass of the layer of heat-resistant material being sub-divided in areas of relatively small size and initially separated by corrugated separating elements of .combustible material, whereby when the panels are set in the furnace wall the combustible material will burn away leaving a corrugated channel between the. contiguous faces of the sub-divided sections.

The invention is illustrated by way of example in the accompanying drawing, in which:

Figure 1 is a view in plan showing one of the panels with which the present invention is coneerned.- f 1 Fig. 2 is a view in transverse section through the panel as lseen. on the line 2 2 of Fig. 1.

Fig. 3 is a. view in transverse section through the panel as seen on the line 3& 3 of Fig. 2`.

Fig. 4 is an enlarged fragmentary view in section showing the manner in which the expansion l Joints are created within the panel.

Referring more particularly to the drawing, IB indicates a at backing plate preferably made of steel of a suitable gauge to give it rigidity,- although it is to be understood that the material l5 may be changed and selected for a suitable condition to be met. Mounted upon the face of the plate I0 and in spaced relation thereto is a series of reinforcing elements I I made preferably of reticulated material. This reticulated material may be welded to the face of the plates i0 as indicated at I2. It is then covered with a, layer of heat resisting and/or insulating material I3. This material may be made of any number of compositions,-the most preferable being a light-weight expanded-mica insulation. Inl order to create expansion joints in the mass of heat-resisting and/or insulating material which has been bonded to the metal plate` I separating elements I4 are disposed upon the plate and extended at right angles thereto. )These separating elements are preferably arrangedv at right angles to each other so as to divide the surface of the plate I0 into a pluralityof spaces of relatively small area. The material of which the separating elements is made is preferably combustible material such as cardboard. These elements are of a desired thickness to form an expansion space between contiguous masses of the heat-resisting and/or insulating material i3. The separating elements 4Q are also preferably formed of corrugated material, the'corrugations extending parallel to the surface of the metal plate whereby sinuous spaces will occur in the mass of heat-resisting and/or insulating material between the faces I5 and I6. It is to be understood that the separators I4 may be arranged to form small units of any desired configuration, although Fig. l of the drawing indicates the separate units at Il as being square. By ,this arrangement it will be seen that the layer of heat-resisting and/or insulating material 'upon the metal plate and combining therewith to form a panel unit` is sub-divided into a plu,- rality of relatively small squares which are delineated initially by intermediate separators made by! a thickness of combustible material. This yreticulated strips material may extend the entire depth of the mal terial I3 or a portion thereof. lIt is intended that` this combustible material shall burn away afterV the panels have been.I installed in the furnace and the furnace has been iired. This will insure that the contiguous faces I5 and I 6 of the segregated sections I'I will be spaced apart and that each of the sections II will be delineated by an expansion be made in combination, construction and-arrangement of parts by thoseskilled in the art, without departingfromlthe spirit of my invention as claimed.

Having thus described my invention, what I A I like, comprising a steel backing plate, bonding space which is corrugated in the normal plane of the panel and will thustend to prevent the ame,

from striking the backingv plate. t

.In operation of the present invention' the panels are made by first forming the backing platesl such forv example as'steel plates, to a desired size and configuration. This vsize and configuration ispreferably square forconvenience in laying the panels in suitable courses on the inner face of a furnace wall. After the panels have been formed bonding members are added, such for example as the II, hich may beJ welded to the outer surface ofwlxie steel plate I0. It is understood that while t is type of reinforcing and bonding element is shown, vother forms of bonding elements might be used if desired. After i the bonding elements have been set in position a layer of heat-resistant and/or insulating'malterial is applied to thel face of the plate III while the separators I4l are held in position suitably.

permitted to set so that the panel comprises a -Afterl the 1ayerla has( been appned the piastic, 30 material of which the layer lI3 is composed -is bonded unit composed of the backing plate and l the heat-'resistant and/or insulating material- -thereon sub-dividedV into sections of relatively small area. The panels ,are then set in suitable position on the furnace wall, and when the furnace is operated the. combustible separators I4 will be burned out from between the contiguous faces I5 and I6 of the sub-divided section I1.

It will thus be seen that by the construction tions delineated by intermediate ,expansion I spaces. y

While I have shown the preferred form of my invention and the .method of making the same, it will be understood that various changes may means carried thereby, a layer of plastic material covering said plate and enveloping the bonding means to make a bondA therewith, and thick-y nesses of combustible material arrangedin uniform spaced relation to each other and imbedded in thelayer of plastic materiaL'the edges extending to the outer face of the plastic material.

2. A heat insulating panel comprising a rec material applied to said sheet envelopingA the bonding members and filling the spaces between the separators to a depth substantially equalling the `height of the spacers as they project from the metal backing plate. f

3. Same as 2 adding the following: said separators being corrugated, the corrugations extending parallel to the plane of the metal plate and the separators being sufficiently stiff to retain their corrugated position while the plastic material is setting, whereby complementary corrugations will beformed in the opposing surfaces of the plastic material. in the space occupied by the combustible separators.

4. `A heat-resistant panel for furnaces and the like comprising a metal backing plate, a layer of plastic material covering said backing plate and being bonded thereto, and thicknesses of brous material arranged in uniform spaced relation to each other and imbedded in the plastic 4wise from the back lplate to substantially the surface of the plastic material and thereby sub-dividing the plastic material into relatively small blocks between which thebrous material occurs. 

